Estimation of optimum machining parameters and surface characterization for WEDM of AA7075/10/Al₂O3 (p) MMC through multi-objective optimization

Ramanujam, R.; Shinde, Pranav A.; Kadam, Rajesh; Dey, Aritra; Shinde, Harshal

doi:10.1016/j.matpr.2018.02.211

Cited by 7 publications

(5 citation statements)

References 8 publications

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“…The fundamental goal of microstructural analysis is to ensure that reinforcement particles are dispersed uniformly throughout the matrix. The optical microscope examines the composite specimens [19]. Figures 5(a)-5(c) show the optical micrographs demonstrating the matrix's homogenous dispersion of reinforcing particles (boron carbide and fly ash).…”

Section: Resultsmentioning

confidence: 99%

Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

Prakash

Sivaprakasam

Garip

et al. 2021

Journal of Nanomaterials

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The present study looks into the effect of WEDM process parameters on the material removal rate (MRR) and surface roughness (SR) responses when machining hybrid composites (Al-Si12/boron carbide/fly ash) using the Taguchi technique. Fly ash and boron carbide (B4C) particles were used for reinforcement (3%, 6%, and 9% by weight), and aluminium alloy (Al-Si12) was used as a matrix material. ANOVA was used to find out the importance of machining factors that affect the quality features of the WEDM process, as well as the relative role of input parameters in determining the WEDM process’ responses. The greatest impact on the response is finalised by the signal-to-noise (S/N) ratio response analysis. However, as a last step, a confirmation experiment with the best combination was carried out to predict and validate the accuracy of the observed values. As the pulse on time and reinforcement increases, MRR also increases. As the gap voltage, wire feed, and pulse off time decrease, it increases. SR is increased by increasing the gap voltage, pulse on time, and pulse off time, wire feed, and reinforcement. The maximum MRR of 38.01 mm3/min and the minimum SR of 3.24 μm were obtained using optimal machining conditions.

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Section: Resultsmentioning

confidence: 99%

Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

Prakash

Sivaprakasam

Garip

et al. 2021

Journal of Nanomaterials

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“…All SEM images were obtained at the 2 μm level. Figure 20 shows the SEM image The shrinkage porosity can be eliminated through the normal heat treatment procedure [33]. On the other side, it has an uneven structure.…”

Section: Machined Surface Analysismentioning

confidence: 99%

Investigation of machining rate and surface roughness in wire EDM of Al6063/WC/ZrO₂ composite using response surface methodology

Janagarathinam,

Subramanian,

Dhanalakshmi

et al. 2024

Mater. Res. Express

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The aim of the current work is to explore the machinability behavior of Al6063/WC/ZrO2 metal matrix composites (MMC) produced through a stir casting process through wire electrical discharge machining (WEDM) process. In order to examine the effects of process parameters such as voltage (V), pulse on time (Ton) and pulse off time (Toff) on material removal rate (MRR) and surface roughness (SR). The experiments were conducted by adapting Response Surface Methodology (RSM) in conjunction with the central composite design (CCD). A second-order regression model has been developed to predict the response parameters and an analysis of variance (ANOVA) was performed to validate the significance of the models. Using the desirability function approach, the parameters were set for the highest MRR and the minimum SR value. The prediction was within a tolerable average error range. A total of 19 sets of tests were developed to obtain six possible solutions. The most suitable solution among these six has been found by a confirmatory experiment. The results indicate that voltage and its interactions have significantly affected both the responses than Ton and Toff. Overall, it can be said that the study of the Al6063/WC/ZrO2 MMCs using WEDM process parameters demonstrated improved casting and machining qualities.

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“…5. Furthermore, the parametric test (F test) and probability values (P value) were also performed [44]. The ANOVA results indicate that, when P values were computed, one of the four machining parameters under investigation had values less than 0.05.…”

Section: Multi-response Optimization Using Grey Relational Analysis (...mentioning

confidence: 99%

Multi-response Optimisation of Wire-EDM for SLMed AlSi10Mg using Taguchi-Grey Relational Theory

Ranganathan,

et al. 2024

Preprint

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The present research effort strives to optimise the multi-response during Wire Electrical Discharge Machining (Wire-EDM) of SLMed AlSi10Mg, applying Taguchi integrated Grey Relational Analysis (GRA). Selective Laser Melting (SLM) represents one of the best-known and most practicable Additive Manufacturing (AM) methods that have the prospective to serve as a replacement for many traditional production processes. Extremely intricate metallic support structures built up during SLM need more attention since they are too difficult to remove by hand. Therefore, post-processing adopting the Wire-EDM precision machining technique is performed in this study to assess the machinability of the SLMed AlSi10Mg as-built part. The multi-response optimisation used here seeks to achieve maximum material removal rate and lowest surface roughness while considering four important influencing elements (pulse On time, pulse Off time, servo voltage, and wire feed rate) at four distinct levels. Taguchi integrated Grey Relational Analysis (GRA) revealed that a pulse On time of 118 µs (Level 3), a pulse Off time of 44 µs (Level 1), a servo voltage of 60 V (Level 4), and a wire feed rate of 7 m/s (Level 4) are suggested to achieve optimal machining of SLMed AlSi10Mg. Furthermore, the derived optimisation results were diligently verified using a confirmatory experiment, and a 38.57% improvement in multi-response characteristics was found when compared to the initial Wire-EDM parameter settings. The methodology suggested in this work offers a standard approach that has the potential to be implemented for the rapid and precise prediction and optimisation of surface roughness while achieving better material removal during Wire-EDM of SLMed AlSi10Mg.

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Estimation of optimum machining parameters and surface characterization for WEDM of AA7075/10/Al₂O3 (p) MMC through multi-objective optimization

Cited by 7 publications

References 8 publications

Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

Investigation of machining rate and surface roughness in wire EDM of Al6063/WC/ZrO₂ composite using response surface methodology

Multi-response Optimisation of Wire-EDM for SLMed AlSi10Mg using Taguchi-Grey Relational Theory

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Estimation of optimum machining parameters and surface characterization for WEDM of AA7075/10/Al₂O3 (p) MMC through multi-objective optimization

Cited by 7 publications

References 8 publications

Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

Investigation of machining rate and surface roughness in wire EDM of Al6063/WC/ZrO2 composite using response surface methodology

Multi-response Optimisation of Wire-EDM for SLMed AlSi10Mg using Taguchi-Grey Relational Theory

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Investigation of machining rate and surface roughness in wire EDM of Al6063/WC/ZrO₂ composite using response surface methodology